The co-packing industry has a transparency problem. Ask most facilities what it costs to run 5,000 pouches and you'll get a callback request, a discovery call, a proposal process, and — if you're lucky — a number three weeks later. We think that's backwards.
So here it is. Every number. No games.
Sachet Filling Pricing — HFFS Only
Overgang runs horizontal form fill seal (HFFS) for powder sachets. Our pricing is tiered by volume so the more you run, the cheaper it gets per pouch. Here's the full table:
| Volume | Price | Per-Pouch Cost |
|---|---|---|
| 1 – 8,000 sachets | $2,330 flat | $0.291 or less |
| 8,001 – 14,000 sachets | $0.28 per pouch | $0.28 |
| 14,001 – 20,000 sachets | $0.27 per pouch | $0.27 |
| 20,000+ sachets | Custom quote | Contact us |
That $2,330 is a flat rate covering all sachet fills up to 8,000 pouches. Whether you run 500 sachets or 8,000, your production cost is $2,330. That structure exists because our costs — machine time, setup, staffing, facility — don't change much based on whether we fill 1,000 pouches or 8,000. The floor is the floor.
Important — Sachets only
This pricing applies to roll stock sachet filling on our horizontal form fill seal machine only. Gusset pouches, zipper pouches, and bench top small runs are quoted on a project basis. Contact us with your specific format and we'll price it accurately.
Blending Costs
If Overgang blends your product, we charge $0.40–$0.60 per pound of finished blend depending on ingredient complexity and mixing requirements. This is separate from your filling cost.
If you ship us a pre-blended powder ready to fill, there is no blending charge. Your call — some brands prefer to control blending in-house, others want us to handle it. Either works.
Flavor Changeovers
Running multiple flavors in one production day is $139 per changeover. A changeover includes stopping the machine, cleaning the fill path, reloading materials, and recalibrating for the new SKU.
Important: the $139 changeover rate applies to same-format, same-film-size SKU changes with no allergen separation required. If your flavors involve allergen changeovers or different pack sizes, pricing is quoted separately. We'll always tell you upfront before you commit.
What the Math Looks Like in Practice
Let's say you want to run 5,000 sachets of a pre-workout blend — pre-blended, single flavor, 30g fill:
- Production run: $2,330
- Blending: $0 (pre-blended)
- Changeovers: $0 (single flavor)
- Total: $2,330
- Effective cost per pouch: $0.466
Now say you want to run 10,000 sachets of two flavors, and Overgang blends both. Assume 50 lbs of blend per flavor (100 lbs total) at $0.50/lb blending:
- Production run: 10,000 x $0.28 = $2,800
- Blending: 100 lbs x $0.50 = $50
- Changeover: 1 x $139 = $139
- Total: $2,989
- Effective cost per pouch: $0.299
The more you run, the cheaper it gets. But the floor is low enough that small brands can afford to prove their concept.
What's Included in the Production Cost
Your $2,330 (or per-pouch rate) covers:
- Machine setup and calibration
- Fill weight verification throughout the run
- Quality checks at regular intervals
- Bulk packout — pouches counted and packed into master cases
- Lot numbers and batch records in your specified format
What's Not Included
- Your bulk ingredients — you source them, they ship to us
- Your roll stock film — you source it, it ships to us
- Assembly (putting pouches into retail boxes) — add-on, quoted separately
- Ecommerce fulfillment — available, quoted separately
- Blending — only if we blend your product
How This Compares to Large Co-Packers
Large facilities with 50,000-unit minimums will quote you lower per-unit tolling costs — maybe $0.18–$0.35/pouch at scale. But that comparison is misleading unless you're actually ready to order 50,000 units and can absorb the ingredient cost, storage cost, and capital tied up in that inventory.
For a brand running 5,000–15,000 sachets to prove a concept or validate a channel, our pricing is genuinely competitive with large facilities when you factor in total cost — not just tolling.
The real comparison
A 5,000-unit run at Overgang: ~$2,330 production + your ingredient cost. The same volume at a facility with a 50,000-unit minimum: you'd need to order 10x the inventory before they'd talk to you. The per-pouch tolling might be cheaper. The total cash out is catastrophically higher.
Frequently Asked Questions About Co-Packing Cost
Is there a minimum order quantity?
For sachet HFFS filling, our minimum is any quantity — the floor price is $2,330. For gusset pouches, zipper pouches, and bench top runs, minimum and pricing are quoted on a project basis.
Do prices include blending?
No. Blending is $0.40–$0.60/lb if Overgang blends. If you ship pre-blended product, there is no blending charge.
What happens if my run takes more than one day?
Additional production days are priced based on your volume and format. We'll estimate your run time when you submit specs and quote accordingly.
Are there setup fees?
No separate setup fees. Machine setup and calibration are included in your production cost.
Do you charge for quality checks or documentation?
No. Lot numbers, batch records, and quality checks throughout the run are included.